Strange suspension noise

Ok I started hearing a clunking noise that sounded like it was coming from the front end about two weeks ago. The noise can be heard best at slow speed when running over rough pavement or making a right hand turn, and appears to be coming from the front passenger wheel. I can not recreate the noise with the car stationary and have tried just about every method I can think of. In all honesty it sounds like a loose wheel, don't ask how I know this, but I have double and triple checked all four. I also had an alignment done and it made no difference and they didn't notice anything either. Yesterday I had the radio off while driving home and I could hear the noise while driving on the freeway around 65-70mph. The noise was bad enough that I decided it was not a good idea to drive the car anymore until I locate the problem.

I have had the car on the lift numerous times and can not find anything loose and I have already checked the front ball joints, tie rods and bushings, but since the noise is not a single clunk I didn't really think that was it. I have also checked the motor mounts, shocks, springs, chassis bracing and drive shaft and all are fine. Hell I even checked the subframe bolts! There is a possibility it is the front sway bar, but everything is tight and the mounts are not cracked and I'm also running the Racing Beat sway bar brace. I'm at a loss so I looking for suggestions from the peanut gallery. Anyone have any ideas?

BTW the car has around 87k miles on it.

Edit: I should add I have also check the exhaust system and it has plenty of clearance and makes no noise when I move it around.

Make sure the eccentric bolts are not eroded/mis-shaped, check the upper control arm bolt for wear, check both ball joins for some resistance, take the wheel off and spin the hub by hand, make sure the shock mounts are tight...and make sure the shock shaft nut is tight (my guess). I have a big-fat rubber band that I use to hold the shaft by hand, then torque the shaft nut. It's possible for NA upper shock mounts to erode internally. Typically if you can't recreate these noises with the car off the ground, it's something damped by the shock.

Did you check the inner tie rods?

Thanks for the suggestions. I have not checked the inner tie rods, but I can't feel any movement in the steering rack nor can I hear any noises when I cylcle the system. That said I have not ruled out the steering rack yet. I'm running Tein Flex coilovers with their top hats but I plan to go back and re-torquing everything so I will check those as well.

If all that does not work I'm thinking one of the front shocks is blown but the car is not handling strangely but who knows.

Different car, had what I thought was a suspension noise when the bolts holding the brake caliper were coming loose. Luckily, I found and fixed the problem.

^^^ +1

I had what I though was a transmission-related rattle. Turned out to be a loose *radiator* support bolt. Completely unrelated but it rattled when I let out the clutch and the drivetrain shuddered a bit. Your "suspension" noise may well be a suspension noise (and Trey has good suggestions above), but you basically have to check everything in the area until you find it.

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Originally Posted by Flyin96M

Ok I started hearing a clunking noise that sounded like it was coming from the front end about two weeks ago.

...but since the noise is not a single clunk

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So is it a rattle? Is it a series of clunks? Maybe you can re-create the noise by running it over a lip in the pavement, such as at the entry to a garage. Maybe you could creep across a 2x4 if you don't have a concrete lip around.

Have you checked the upper shock mounts? Edit: Trey beat me to this.

Re-check the bushings and ball joints by watching them move under load. Inspect this by supporting the frame on jack stands and loading/unloading the suspension with a floor jack under the tire. Be careful not to load the wheel enough to lift the car off of the jack stand.

So i finally found it after checking every damn nut and bolt! Apparently while there is plenty of clearance normally the motor would lean just enough for the exhaust to contact my butterfly brace while turning right or when I would hit rough pavement. I just adjusted the brace some and now the noise is gone and I plan to celebrate with a beer or three. *I must have checked the clearance on that half a dozen times and had even tried shaking the exhaust to see if it was hitting anything. Thank for for everyone's input.

I made a semi hard mount for my exhaust. It works great and even survived two days at Harris Hill where I have a history of breaking hangers.
http://a7.sphotos.ak.fbcdn.net/hphot...55807952_n.jpg

Thanks for the idea I might look into doing something like that. I was also looking at these motor mounts sold by Goodwin Racing as they look like they flex less than the Mazdaspeed mounts.